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IS 13043 (1991): Covered Manual Metal Arc Welding

Electrodes - Determination of Efficiency, Metal Recovery
and Deposition Co-efficient [MTD 11: Welding General]

“!ान $ एक न' भारत का +नम-ण”

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है”
ह
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“Knowledge is such a treasure which cannot be stolen”
 ( Reaffirmed 2003 )

Indian Standard
COVERED MANUAL METAL ARCWELDING
ELECTRODES- DETERMINATION OF
EFFICIENCY,METAL RECOVERY AND
DEPOSITION CO-EFFICIENT

UDC 621’791’753:0424:620’16

@ BIS 1991

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
my 1991 Price Group 1
Welding General Sectional Committee, MTD 11

FOREWORD
This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalizedby the
Welding General Sectional Committee had been approved by the Metallurgical Engineering Division
Council.
This standard has been formulated with a view to help the manufacturer and use of covered welding
electrodes to determine the efficiency, metal recovery and deposition coefficients.
In the formulation of this standard assistance has been derived from IS0 2401:1972 Covered elec-
trodes -. Determination of efficiency, metal recovery and deposition coefficient, issued by the Inter-
national Organisation for Standardization.
For the purpose of deciding whether a particular requirement of this standard is complied with, the
final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in
accordance with IS 2:1960 ‘Rules for rounding off numerical values ( revised )‘. The number of signi-
ficant places retained in the rounded off value should be the same as that of the specified value in this
standard.
 Indian Standard
COVERED MANUAL METAL ARCWELDING
ELECTRODES-
-~ DETERMINATION OF
EFFICIENCY,METAL RECOVERY AND
DEPOSITION CO-EFFICIENT

1 SCOPE is to be used. Approximate dimensions of test

plate shall be:
1.1 This standard covers method for determina-
tion of eficiency, metal recovery and deposition Length - 300 mm
co-efficients of covered MMAW electrodes up to Width - 75 mm
6’3 mm size. Thickness -- IOmm
2 TERMS AND DEFINITIONS If it is found that the length of weld exceeds the
length af the test plate, the weld bead may be
2.1 Nomiaal Electrode Efficiency, EN allowed to run continuous to but at rightangle to
the run so as to follow the contour of the plate.
This is the ratio of the mass of weld metal
deposited under standard conditions to the The test plate surface shall be thoroughly cleaned,
mass of nominal diameter core wire consumed. if necessary, by brushing and light grinding, to
make it free from rust, scale, paint, oil, grease, etc.
2.2 Effective Electrode Efficiency, EE The plate shall be weighed to I g accuracy before
and after welding.
This is the ratio of the mass of weld metal
deposited under standard conditions to the actual 3.2 Weld Deposition
mass of core wire consumed.
3.2.1 Electrodes
2.3 Depositim Efficiency, ED
Usually five electrodes of same brand and batch
This is the ratio of mass of weld metal deposited shall be used for weld deposition. If the metal
under standard conditions to the total mass of a yield from each electrode exceed IO0 gms, three
given electrode consumed, exclusive of stub ends. electrodes may only be used. The electrodes shall
be weighed before testing to an accuracy of 1 g.
2.4 Weld Metal Recovery, Rw Another set of equal number of electrodes shall
be carefully defluxed and the weight of the clean
This is the ratio of the mass of weld metal core wire shall be measured to an accuracy of
deposited under standard conditions to the total 1 g. The mass of the core wire can also be cal-
mass of a given electrode tested. culated by measuring the diameter and length of
the wires carefully and calculating the mass on
2.5 Deposition Co-Efficient, CD
the basis of density of steel taken as 7’85 g,cm”.
This is the mass of the weld metal deposited 3.2.2 Welding Current
under standard conditions per ampere minute for a
given electrode. The welding current shall be about 90 percent of
the maximum value of the range recommended by
NOTF W-bile rcportil;g the data, a further suffix shown
below ma! hc added to indicate the type of current the electrode manufacturer for flatposition. The
LlXd. current shall be measured by a dampened am-
meter of Class 2 precision. For AC, the root
Type qf Current SUsJ;.Y Example mean square ( RMS > value of the current shall
+ Rw+ be measured. The machine setting shall not be
DC Positive
DC Negative - Rw- changed during the test. For calculation purposes,
- Rw- the average value of the current shall be used.
AC
3 EVALUATION PROCEDURE 3.2.3 Polarity and Arc Voltage

3.1 Test Plate The electrodes suitable for DC only, shall be tes-
ted on the DC with the polarity recommended by
For each diameter of electrode to be tested, one electrode manufactuerer. The electrodes suitable
test plate of carbon steel with 0’25 percent C(max) for either DC or AC, shall be tested on AC.

1
IS 1304k 1991

In the later case, the transformer used shall have be weighed to an accuracy of Lt 1 g. The plate
following characteristics: shall be dried before weighing, if water cooling is
employed.
a) the transformer should have an open circuit 4 CALCULATION OF EFFICIENCY, METAL
voltage not higher than 10 V than the mini-
mum value indicated for the electrode. RECOVERY, AND DEPOSITlON
CO-EFFICIENTS
b) the form factor ( ratio of RMS value and Efficiency, metal recovery and deposition co-
mean value ) of current in short circuit efficients may be calculated as follows:
condition for the setting used in welding,
should fall within the limit 1’1 1 < F < 1’2. Nominal electrode efficiency, EN = F
M2
M4 - M7
The arc length, arc voltage and welding procedure M2
shall be typical of the electrode being used and Effectjve electrode efficiency, k$ .--
M3 -~~ M,;
the deposited bead shall be free from major defects.
f4f2
Deposition efficiency, ~0
3.2.4 Welding Position MI - !d~,
The electrodes shall be deposited in down hand Weld metal recovery, Rw M2
( flat ) position only without any interruption till W
a stub length of 40 mm approx remains.
Deposition co-efficient, CD ==’ yr
3.2.5 Arcirzg Time
where
The arcing time of each electrode shall be Ml = mass of electrodes, in g.
measured with a precision of i: O-2 sand total time
for the electrodes shall be c ilculated in minutes. >%I2== mass of deposited weld metal, in g.
M3 = total mass of core wire ( actual ) in g.
3.2.6 Stub Ends
M4 :=: total mass of core wire as calculated
Stub ends shall be carefully retained after welding on the basis of nominal diameter, in g.
each run. The stub ends shall be weighed to 2 1 g
accuracy to obtain following data: &I:, - mass of stub ends with unfused cover-
ing, in g.
a) Total weight in grams without loss of
unfused covering. _ Ms = mass of core wire ( actual ) in the stub
end, in g.
Total weight of the core wire after removal A47 : mass of nominal ccre wire in stub ends
of the covering, and as calculated, in g.
cl Total length of unfused core wire to ri 1 Lx = length of the core, wire of the electrodes
mm to determine measured total length of in cm.
stub ends. The total length of stub ends L2 z= length of core wire of the stub ends,
shall be between 175 and 250 mm for a in
sample of 5 electrodes and 105 and 135 cm.
mm for the 3 electrodes samples. r- average welding current, in amperes.
3.2.7 Cooling A,fter We/ding t = total arcing time, in -minutes.
The test plate may be cooled in water after depo- For calculating nominal efficiency the core wire
mass M4 and Mr may be computed by the follo-
siting each run. Interpass temperature shall not
exceed IOO’C. Slag and spatter shall be thoroughly wing formulae:
removed and the plate dried completely before
depositing the subsequent run.
After completion of welding, the test plate shall
be cooled to room temperature. Slag and spatter
shall be carefully removed and then the plate shall where d =nominal diameter of electrode in mm.

2
Standard Mark

The use of the Standard Mark is governed by the provisions of the Bureau of Indian Standards
Act, 1986 and the ~Rules and Regulations made thereunder. The Standard Mark on products
covered by an Indian Standard conveys the assurance that they have been produced to comply with
the requirements of that standard under a well defined system of inspection, testing and quality
control which is devised and supervised by BIS and operated by the producer. Standard marked
products are also continuously checked by BIS for conformity to that standard as a further safe-
guard. Details of conditions under which a licence for the use of the Standard Mark may be granted
to manufacturers or producers may be obtained from the Bureau of Indian Standards.